M&M RWB series User manual

M&M Refrigeration, Inc.
Computer Control System
Screw Compressor Control
RWB Series
Retro Fit Panel
&

Standard Screw Compressor - RWB Series
M&M REFRIGERATION INC.
Copyright protection claimed includes all forms and matters now and hereinafter granted pro-
tection by statutory or judicial law, including unlimited protection for screen images generated
from the software programs. Such images include but are not limited to windows, icons, and
report displays.
This manual is provided without any warranty of any kind, either expressed or implied. M&M
Refrigeration, Inc., shall not be liable to any person or entity with respect to any liability, loss,
or damage to be caused directly or indirectly by this manual. Information in this document is
subject to change without notice, and does not represent a commitment on the part of the
vendor. The software described in this manual is furnished under a license agreement and
may be used or copied only in accordance with the terms of the agreement. No part of this
document may be reproduced or transmitted in any form or by any means, electrical or
mechanical including photocopying, for any purposes, without permission from M&M Refriger-
ation, Inc.
M&M Refrigeration Inc., Screw Compressor Manual - RWB Series
Version 200
© M&M Refrigeration, Inc., 1992-2002
All Rights Reserved.
M&M Refrigeration, Inc.
412 Railroad Ave., Suite #1
P.O. Box 449
Federalsburg, MD 21632
Phone [phone] FAX [phone]
Printed in the United States of America.

M&M REFRIGERATION INC.
Revision History
Revision Date Change
- 11/2002 Inital Release

Standard Screw Compressor - RWB Series
M&M REFRIGERATION INC.

M&M REFRIGERATION INC.iii
Table of Contents
Table of Contents
CHAPTER 1 CCS Introduction
Associated Documents.................................................................. 1-1
Applicable Compressor Models.................................................... 1-1
CHAPTER 2 General Operating Overview
Definitions..................................................................................... 2-1
Keypad Functions ......................................................................... 2-2
Main Screen Overview ................................................................. 2-4
Hot Key Selection ......................................................................... 2-5
Screen Types ................................................................................. 2-5
Menu Screens ........................................................................... 2-6
Data Entry Screens ................................................................... 2-7
Data Entry Procedures.......................................................... 2-8
Field Types....................................................................... 2-8
Selectable Fields.......................................................... 2-9
Numerical Data Input Fields ....................................... 2-9
Absolute Pressure Fields ............................................. 2-9
Time Fields .................................................................. 2-10
Date Fields................................................................... 2-10
String Fields ................................................................ 2-10
Telephone Number Field ............................................. 2-11
Hexadecimal Fields ..................................................... 2-11
Status Screens ........................................................................... 2-12
Confirmation Screens ............................................................... 2-13
Confirmation Screen Procedures.......................................... 2-14
Momentary Screens .................................................................. 2-14
Information Screens.................................................................. 2-15
Access Screens ......................................................................... 2-15
Log Screens .............................................................................. 2-17
Alarms & Failures......................................................................... 2-18
CHAPTER 3 Compressor Controls
Modes Of Operation ..................................................................... 3-1
Lubrication System ....................................................................... 3-2
Oil Pump Configuration ........................................................... 3-2

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Oil Pressure Calculations ......................................................... 3-3
Oil Level Indication.................................................................. 3-3
Starting the Screw Compressor..................................................... 3-3
Manual Mode............................................................................ 3-4
Automatic Mode....................................................................... 3-5
Remote/Auto Remote Mode..................................................... 3-5
I/O Control ........................................................................... 3-5
Network Control................................................................... 3-5
Sequenced Mode ...................................................................... 3-5
Stopping the Screw Compressor................................................... 3-6
Manual Mode............................................................................ 3-6
Automatic Mode....................................................................... 3-6
Remote Mode ........................................................................... 3-6
I/O Control ........................................................................... 3-6
Network Control................................................................... 3-6
Sequenced Mode ...................................................................... 3-7
Capacity Control ........................................................................... 3-7
Computed Slide Valve Position ................................................ 3-7
Manual Capacity Control ......................................................... 3-7
Automatic Capacity Control..................................................... 3-7
Control Groups..................................................................... 3-8
Time Proportional Control Strategy..................................... 3-8
Remote Capacity Control ......................................................... 3-11
I/O Control ........................................................................... 3-11
Network Control................................................................... 3-11
Auto-Remote Capacity Control................................................ 3-11
I/O Control ........................................................................... 3-11
Network Control................................................................... 3-12
Sequenced Capacity Control .................................................... 3-12
Low Alarm and Failure Setpoints ........................................ 3-12
Running in Trim Mode......................................................... 3-12
Running in Full Load Mode................................................. 3-13
Anti-Cycle in Sequenced Mode ........................................... 3-13
Forced Unloading & Limiting .................................................. 3-13
Ramp Start ................................................................................ 3-13
Slide Valve Position Ramp Start Limiting................................ 3-14
Unload Solenoid Configuration ........................................... 3-15
Setpoint Scheduling ...................................................................... 3-15
Daily Schedules ........................................................................ 3-15
Weekly Schedule ...................................................................... 3-15
Variable Vi Slide Stop Control...................................................... 3-16
Vi Adjustments..................................................................... 3-16
Manual Vi Adjustment ......................................................... 3-16
Vi Slide Stop and Capacity Slide Valve Interference ............... 3-16

M&M REFRIGERATION INC.v
Table of Contents
Oil Temperature Regulation.......................................................... 3-17
Liquid Injection Oil Cooling (Option).......................................... 3-17
Single Port Liquid Injection ..................................................... 3-17
Dual Port Liquid Injection........................................................ 3-17
Anti-Cycle Timer .......................................................................... 3-17
Power Fail Restart......................................................................... 3-18
Remote Status Information....................................................... 3-18
Process Temperature Control (Option) ......................................... 3-18
Economizer Control (Option) ....................................................... 3-19
Automatic Mode ....................................................................... 3-19
Manual On Mode...................................................................... 3-19
Manual Off Mode ..................................................................... 3-19
Sequenced Mode....................................................................... 3-19
Power Assist (Option)................................................................... 3-19
Operational Procedures................................................................. 3-20
START Hot Key ....................................................................... 3-20
STATS Hot Key ........................................................................ 3-22
Compressor Main Status Screen .......................................... 3-22
Status Banner ................................................................... 3-23
System Current State ....................................................... 3-24
Mode Area ....................................................................... 3-24
Alarm & Failure Area ...................................................... 3-25
Compressor Graphics Screen ............................................... 3-25
Energy Status Screen............................................................ 3-26
Operating Hours Screen ....................................................... 3-27
Variable VI Status Screen..................................................... 3-28
Economizer Status Screen (Option) ..................................... 3-29
Active Alarms & Failures Status Screen.............................. 3-30
Auto-Start Warning Screen .................................................. 3-31
MODE Hot Key........................................................................ 3-32
Local Mode .......................................................................... 3-32
Manual Mode ....................................................................... 3-32
Automatic Mode................................................................... 3-32
Remote Mode ....................................................................... 3-33
Auto-Remote Mode.............................................................. 3-33
Sequenced Mode .................................................................. 3-33
SETPT Hot Key ........................................................................ 3-34
Pressure Setpoints ................................................................ 3-34
Suction Pressure Control Groups..................................... 3-34
High Suction Pressure Setpoints...................................... 3-36
Discharge Pressure Setpoints........................................... 3-37
Oil Pressure Setpoints...................................................... 3-38
Oil Filter Pressure Setpoints ............................................ 3-39

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vi M&M REFRIGERATION INC.
Temperature Setpoints.......................................................... 3-40
Discharge Temperature Setpoints .................................... 3-40
Oil Temperature Setpoints (without Liquid Injection) .... 3-41
Oil Temperature Setpoints ( with Liquid Injection)......... 3-42
Process Temperature Control Group................................ 3-43
High Process Temperature Selection ............................... 3-44
Motor Current Setpoints....................................................... 3-45
Slide Valve Setpoints............................................................ 3-46
SCHED Hot Key ...................................................................... 3-47
Control.................................................................................. 3-47
Active Group........................................................................ 3-48
Active Schedule ................................................................... 3-49
Weekly Schedule .................................................................. 3-50
Daily Schedules.................................................................... 3-50
Schedule 1 To Schedule 7................................................ 3-51
CNTRL Hot Key ...................................................................... 3-52
Suction Pressure Control Setpoints...................................... 3-52
Process Temperature Control Setpoints ............................... 3-53
Economizer Control Setpoints (Option)............................... 3-54
Variable VI Setpoints (Option)............................................. 3-55
MISC Hot Key.......................................................................... 3-56
LOGS Hot Key ......................................................................... 3-57
MENUS Hot Key ..................................................................... 3-57
CHAPTER 4 Logging Functions
Logging Functions Technical Overview....................................... 4-2
Operations Log ......................................................................... 4-2
Trend Log ................................................................................. 4-2
Alarm Log ................................................................................ 4-2
Failure Log ............................................................................... 4-2
User Log ................................................................................... 4-2
KW Log (Optional) .................................................................. 4-3
System Log (Optional) ............................................................. 4-3
Logging Functions Operating Procedures .................................... 4-4
Operations and Trend Logs ...................................................... 4-5
Alarm and Failure Logs............................................................ 4-6
User Log ................................................................................... 4-7
KW Log (optional) ................................................................... 4-8
Clear Logs ................................................................................ 4-9
Clear Std Log ....................................................................... 4-9
Clear System Log (Optional) ............................................... 4-9
Clear All Logs...................................................................... 4-9
Set Log Rates ....................................................................... 4-9

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Table of Contents
CHAPTER 5 Menu Functions
Technical Overview ...................................................................... 5-1
Logon User ............................................................................... 5-1
Logoff User............................................................................... 5-1
Automatic Log Off ............................................................... 5-1
Diagnostics Menu ..................................................................... 5-2
System Information.............................................................. 5-2
View Discrete I/O................................................................. 5-2
View Analogs ....................................................................... 5-2
View Dip Switches ............................................................... 5-2
View Network Comm .......................................................... 5-2
Override Discrete I/O (Option) ............................................ 5-3
Setup Menu............................................................................... 5-3
Set Date and Time ................................................................ 5-3
Calibrate Sensors.................................................................. 5-3
Dynamic Sensor Calibration............................................ 5-3
Static Sensor Calibration ................................................. 5-4
Password Control ................................................................. 5-4
Adding/Deleting Users .................................................... 5-4
Screen Access Levels....................................................... 5-4
Initialization ......................................................................... 5-5
Power Fail Reset .............................................................. 5-5
Set Factory Configuration................................................ 5-5
Configuration ....................................................................... 5-5
Display Setup................................................................... 5-5
Communication................................................................ 5-5
Motor Configuration ........................................................ 5-5
Set Operating Status......................................................... 5-5
Operational Procedures................................................................. 5-6
Logon User ............................................................................... 5-7
Logoff User............................................................................... 5-7
Diagnostics ............................................................................... 5-8
System Information.............................................................. 5-9
View Discrete I/O................................................................. 5-10
View Analogs ....................................................................... 5-11
View Dip Switches ............................................................... 5-12
View Network Comm .......................................................... 5-13
Override Discrete I/O........................................................... 5-14
Setup ......................................................................................... 5-15
Set Date & Time.................................................................. 5-16
Calibrate Sensors.................................................................. 5-17
Dynamic Sensor Calibration............................................ 5-18
Static Sensor Calibration ................................................. 5-19

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viii M&M REFRIGERATION INC.
Password Control ................................................................. 5-19
Add/Delete User .............................................................. 5-20
Screen Access Levels ...................................................... 5-21
Initialization ......................................................................... 5-22
Power Fail Reset .............................................................. 5-23
Set Factory Config........................................................... 5-24
Configuration ....................................................................... 5-25
Display............................................................................. 5-26
Communication Setup ..................................................... 5-27
Motor Configuration........................................................ 5-28
Set Operating Status ........................................................ 5-29
APPENDIX A Alarm and Failure Data
Analog Alarms.............................................................................. A-1
Discrete Alarms ........................................................................... A-3
APPENDIX B Analog and Discrete I/O
Analog Inputs................................................................................ B-1
Discrete I/O RACK 1.................................................................... B-2
APPENDIX C Communication Protocols
Introduction................................................................................... C-1
Applicable Documents.................................................................. C-1
Hardware Interface Description.................................................... C-2
Hardware Requirements ........................................................... C-2
Interface Connections............................................................... C-2
Message Addressing................................................................. C-4
Software Interface Description ..................................................... C-7
Protocol Overview.................................................................... C-7
Status Only or Status and Control Options............................... C-7
Message Categories .................................................................. C-7
MODBUS Protocol Description............................................... C-8
Read Holding Registers........................................................ C-8
Preset Single Register .......................................................... C-9
Preset Multiple Registers ..................................................... C-9
Error Messages..................................................................... C-9
DF1 Protocol Description......................................................... C-11
Protected Typed Logical Read ............................................. C-11
Protected Typed Logical Write............................................. C-12
Word Range Read................................................................. C-12

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Table of Contents
Word Range Write................................................................ C-12
Error Messages..................................................................... C-13
Data Formats................................................................................. C-13
Status Message Description .......................................................... C-14
Analog Inputs and Computed Parameters ................................ C-14
Discrete Input and Outputs....................................................... C-15
Alarm and Failure Data ............................................................ C-16
Equipment Data ........................................................................ C-18
Control Message Description........................................................ C-22
Network In Control Command................................................. C-23
Compressor Start/Stop Command ............................................ C-23
Set Compressor Mode Command............................................. C-24
Change Compressor Capacity Command................................. C-24
Acknowledge/Clear Active Alarm Command.......................... C-24
Change Current Setpoint Group Command.............................. C-24
Set Economizer Mode Command............................................. C-25
Auto Start/Stop Control Command .......................................... C-25
Suction Pressure Setpoint Message Description........................... C-26
Process Temperature Setpoint Message Description .................... C-27

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M&M REFRIGERATION INC.1-1
CHAPTER 1 CCS Introduction
The Compressor Control System (CCS) is an advanced microprocessor-
based control system designed for efficient and automatic control and mon-
itoring of industrial refrigeration systems including screw compressors. The
controller is composed of a microprocessor board, Input/Output boards, a
keypad, and a Liquid Crystal Display (LCD). The system uses the LCD to
present screens to the operator for information review and control.
The Screw Compressor User’s Manual provides the operator with the basic
information needed to configure and operate the compressor. The manual
is divided into several sections beginning with the General Operating Over-
view which contains system definitions, keypad functions, main LCD screen
layout, screen type designations, and generic alarm & failure information.
The remaining sections of the manual cover the control functions required
for operation of the compressor and detailed descriptions of the display
screens found in the system. Also included are appendices covering stan-
dard communications protocols, hardware channel assignments, and alarm
descriptions.
Associated Documents
Familiarity with the following M&M documents is recommended:
• CCS Sequencer Control
Applicable Compressor Models
This document covers the M&M RWB Compressor retrofit.

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M&M REFRIGERATION INC.2-1
CHAPTER 2 General Operating Overview
The following sections will give the user an overview of the general operat-
ing procedures for the CCS.
Definitions
CCS System Manager is the person who will assign user passwords,
access levels and screen access requirements.
Cursor is a field indicator used on data entry screens. There are four possi-
ble cursor types:
•*represents a number field input
•>represents a selectable field
•“represents a string field
•Xrepresents a hexadecimal field
The cursor shows the user which fields are changeable on a data entry
screen.
Display Area is the part of the LCD display that shows system information.
The display area will vary in size depending on whether a large character or
small character screen is being viewed.
Fields are places where the user enters control parameters.
Highlight is when the letters appear light on a dark background instead of
dark on a light background. The highlighted area may flash from light to
dark to stress its importance, and to gain the user’s immediate attention.
Hot Keys are the top-level system functions and menus. The hot keys are
located in a column on the left side of all large character screens.
Large Character Screens are screens that use large, double high charac-
ters, and contain the title banner and hot keys.
Main Status Screen is a large character status screen, which is considered
the main system status screen. This screen will also contain the alarm sta-
tus, mode, and state of the system.

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2-2 M&M REFRIGERATION INC.
Parameter is a system control value, which is displayed by the system or input by the user.
Examples are suction pressure and high suction pressure alarm setpoint.
Screen is a method of displaying information to the user. The system contains eight types of
possible screens: menu screens, data entry screens, status screens, confirmation screens,
momentary screens, information screens, access screens, and log screens
Small Character Screens utilize the entire LCD display and use small characters to show
system information. These screens do not display the system hot keys.
Toggle is the process of moving from one selectable choice to the next by using the ENTER
key.
User is an individual or group of individuals who will use the system. A user is identified by a
user number ranging from 1 to 10. The user may also be referred to as the operator in this
document.
Keypad Functions
The following is a brief summary of the CCS keypad along with a description of its individual
keys. Below is a drawing of the CCS keypad layout.
Keypad Diagram

M&M REFRIGERATION INC.2-3
Chapter 2: Keypad Functions
STOP The red STOP key causes an immediate and orderly shutdown of a compressor. This
key usually has no effect on master panels.
SHIFT The SHIFT key is used to switch control back and forth from the display area to the hot
keys. This key may also be used to scroll between the horizontal pages of a log screen.
0 – 9 The NUMBER keys select menu or hot key options. On data entry screens the number
keys are used to enter numerical data.
•The DOT key allows decimal point entry on data entry screens. This key also permits
the user to page forward one full screen at a time on log and status screens.
-The MINUS key allows negative number entry on data entry screens. This key also per-
mits the user to page back one full screen at a time on log or status screens.
On data entry or menu screens, the UP ARROW key moves the cursor up to the next
item on the screen.
On data entry or menu screens, the DOWN ARROW key moves the cursor down to the
next item on the screen.
On data entry or menu screens, the LEFT ARROW key moves the cursor left to the next
item on the screen. This key also permits the user to page forward one full screen at a
time on log and status screens.
On data entry or menu screens, the RIGHT ARROW key moves the cursor right to the
next item on the screen. This key also permits the user to page back one full screen at
a time on log and status screens.
PG UP The PG UP key is used to page back one full screen at a time for status screens or to
page up to more current data on log screens.
PG DN The PG DN key is used to page forward one full screen at a time for status screens or to
page down to older data on log screens.
QUIT The QUIT key exits the current screen and displays the previous screen. Pressing the
QUIT key to exit from a data entry screen will result all changed data being lost.
SAVE The SAVE key is used with data entry screens to save any changed information. It also
exits the current screen and displays the previous screen.
CLEAR The CLEAR key within data entry screens will erase the current number field. On the
main status or alarm status screen it acknowledges and clears alarms and failures.
ENTER
The ENTER key is used within data entry screens on a number field to accept numerical
data or on a selectable field to toggle through the available choices. On menu screens,
the ENTER key will select the highlighted menu item. The ENTER key may also be
used to scroll forward through the status screens.
The CONTRAST keys are used to adjust the display for proper viewing depending on
the ambient light levels. When the desired contrast is achieved, pressing any other key
will lock the current contrast value into memory.

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Main Screen Overview
The Main Screen is the name for a set of features common to all large character screens. The
Main Screen is broken down into three areas: display area, hot keys, and title banner. The fol-
lowing drawing shows a representation of the main screen layout and labels each of its vari-
ous areas.
Main Screen Layout
Title Banner - The top highlighted bar contains the M&M logo and the current time of day and
may only be found on large character screens.
Display Area - Contains all of the detailed screen information. Large character screens will
use only the designated display area, while small character screens use the entire LCD dis-
play.
Hot Keys - The hot keys are a set of system functions, which are found in a column on the left
side of all large character screens. They are the most frequently used functions on the CCS
and allow access to all lower level menus and functions.
M & M REFRIGERATION 8:32 AM
1. START
2. STATS
3. MODE DISPLAY AREA
4. SETPT
5. SCHED
6. CNTRL
7. MISC
8. LOGS
9. MENUS
TITLE BANNER
H
O
T
K
E
Y
S

M&M REFRIGERATION INC.2-5
Chapter 2: Hot Key Selection
Hot Key Selection
1. Verify Number next to a Hot Key is Highlighted -one of the numbers next to a hot
key should be highlighted and flashing. (This is not the same as having the hot key
command highlighted.)
If there are no numbers highlighted, switch control from the display area to the hot
keys by pressing the SHIFT key.
2. Select Option - use the key pad to select a corresponding option number or use the
arrow keys to move the highlighted area to the desired selection and press ENTER.
3. Alternate Select Option - whenever a status screen is being displayed, a hot key
may be activated by typing the hot key number. This also works on small character
status screens even though the hot keys are not visible.
Screen Types
CCS information is presented to the operator using eight different types of screens. The differ-
ent screen types each use specific data entry and control procedures. The screen types let the
user know which screen type heading to refer to for information on the specific screens' proce-
dures. The following is a list of the eight different screen types.
• Menu Screen - displays a numbered list of options.
• Data Entry Screen - used to modify system control parameters.
• Status Screen - displays real-time system summary data.
• Confirmation Screen - used for verification, gives a choice for a yes or no option.
• Momentary Screen - displays a message for three seconds.
• Information Screen - used to display system information
• Access Screen - a menu type screen with an number input field.
• Log Screen - displays a record of system parameters and actions.

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Menu Screens
The Menu screen is used to present the user with choices for various system operations.
Menu screens are found throughout the CCS system. The following is an example of a
menu screen.
Menu Screen
The following table contains a list of the active keys on a menu screen and their function.
Menu Screen Keys Table
M & M REFRIGERATION 8:32 AM
1. START
2. STATS SETPOINT SELECTIONS
3. MODE
4. SETPT 2.TEMPERATURE
5. SCHED 3.MOTOR CURRENT
6. CNTRL 4.SLIDE VALUE POS
7. MISC
8. LOGS
9. MENUS
KEYS FUNCTION
SHIFT Switches control back and forth between the display area and the hot
keys.
NUMBER
KEYPAD Used to choose a selection number.
ENTER Used to choose the selection number that is highlighted.
UP/DOWN
ARROW Moves the cursor from one selection to the next either up or down.
QUIT Exits from current screen to the previous screen.
1.PRESSURE